Systems, methods, and software for automated design and manufacturing of hvac control panels

ABSTRACT

The present inventors devised, among other things, systems, methods, and software that radically simplify and reduce the time necessary to specify, design, manufacture, and document control panels and wiring harnesses for semi-custom and custom equipment, such as HVAC equipment. One exemplary system includes a computerized product configuration module that defines product family parameters from user input and outputs a product family data structure, for example, a coded character string, to a technical design module. The technical design module, which incorporates engineering design rules for control panels and wiring modules, automatically processes the coded character string, outputting detailed engineering drawings, component listings, and even assembly instructions to robotic manufacturing equipment. The exemplary system dramatic reduces the product specification and engineering time required for any custom control panel and makes it possible for OEMs to efficiently offering more options and shorter turn-around times to its customers.

RELATED APPLICATION

The present application claims priority to U.S. Provisional Application60/963,747, which was filed on Aug. 6, 2007, and U.S. Ser. Appl. No.12/228,258, which was filed on Aug. 6, 2008. These applications areincorporated herein by reference.

COPYRIGHT NOTICE AND PERMISSION

A portion of this patent document contains material subject to copyrightprotection. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in the Patent and Trademark Office patent files orrecords, but otherwise reserves all copyrights whatsoever. The followingnotice applies to this document: Copyright © 2007, Design ReadyControls, Inc.

1. Technical Field

Various embodiments of the present invention concern automated designand manufacture of equipment control panels, such as control panels forheating ventilation and air conditioning (HVAC) equipment. Someembodiments also concern control panels and other subassemblies, such aswiring harnesses, for the design and manufacture of pumps, largecompressors, conveyors, packaging, and air-handling equipment.

2. Background

Equipment, such as HVAC equipment, is manufactured by Original EquipmentManufacturers (OEMs) which have a variety of customers with differingneeds. To meet these needs efficiently, OEMs develop semi-custom productlines, or product families, for particular market segments . Customersthen select among various lists of parameters, configurations, andoptions of the product family to order semi-customized equipment in muchthe same way as automobile buyers customize their automobiles bychoosing among available options.

For example, an HVAC equipment customer might choose among parameters,such as cooling capacities and electrical supply voltages, and amongconfigurations, such as numbers and sizes of supply and exhaust fans. Byselecting particular parameters, configurations, and options, thecustomer is ultimately choosing a single product from thousands or evenmillions of unique possibilities.

Once the HVAC customer has committed to its selections by placing anorder, an HVAC OEM typically completes the order using an ETO (EngineerTo Order) process. Specifically, this process entails passing the orderto a team of engineers, who study the selections and adapt or customizea generic electrical and mechanical design to incorporate the customerselections. Among other things, this customization effort frequentlyrequires redesigning the electrical control panel of the HVAC equipment.

However, one problem recognized by the current inventors is thatconventional control panel redesign is particularly time consuming andexpensive because the control panel functions as the brains of the HVACequipment, and includes hundreds of interconnected components. Thisadded time and expense places significant pressure on OEMs to limit therange of options they offer customers in a market where many customersare actually wanting more options and lower pricing.

Moreover, because of this timing and pricing pressure, many OEMs havesought to shorten the conventional design and manufacture process byskipping steps such as fully documenting their control panel designswith accurate as-built drawings. However, the lack of these drawingscreates the further problem of making it difficult to service andtroubleshoot HVAC equipment after installation.

Accordingly, the present inventors have identified a need for betterways of designing and manufacturing OEM equipment generally, and HVACcontrol panels particularly.

SUMMARY

To address this and/or other needs, the present inventors devised, amongother things, systems, methods, and software that radically simplify andreduce the time necessary to specify, design, manufacture, and documentcontrol panels for semi-custom or even fully custom OEM equipment, suchas control panels and wiring harnesses for HVAC equipment. One exemplarycomputerized system includes a product-configuration module, atechnical-design module, and a manufacturing module.

In operation, the product-configuration module receives user input aboutproduct family parameters through a specialized configuration interface,and outputs a product family data structure, for example a codedcharacter string analogous to human DNA, to the technical-design module.The technical-design module, which incorporates engineering designrules, automatically processes the coded character string, outputtingtrue as-built engineering drawings, component listings, wiring listings,and even assembly instructions for robotic manufacturing equipment. Themanufacturing module receives output of the technical-design module,generates and orders parts using an enterprise resource planning system,and communicates assembly instructions to robotic manufacturingequipment.

The exemplary system dramatically reduces the product specification andengineering time required for any custom control panel and makes itpossible for OEMs to efficiently offer more options and shorterturn-around times to its customers and thus enjoy a significantcompetitive advantage.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a block diagram of an exemplary control panel design andmanufacturing system 100, which corresponds to one or more embodimentsof the present invention.

FIG. 2 is a flow chart of an exemplary method of operating system 100,which corresponds to one or more embodiments of the invention.

FIG. 3 is a facsimile of exemplary graphical user interface 300corresponding to one or more embodiments of the present invention.

FIG. 4A is a tabular rendition of an exemplary control panel DNA datastructure which corresponds to one of more embodiments of the presentinvention.

FIG. 4B is a tabular rendition of an exemplary option-to-coded-stringtranslation table corresponding to one or more embodiments of thepresent invention.

FIGS. 5A and 5B are combination flow and block diagrams, which takentogether, represent an exemplary architecture 500 that corresponds toone or more embodiments of the present invention.

FIG. 6 is a facsimile of exemplary graphical user interface 600corresponding to one or more embodiments of the present invention.

FIG. 7 is a facsimile of exemplary graphical user interface 700corresponding to one or more embodiments of the present invention.

FIG. 8 is a facsimile of exemplary graphical user interface 800corresponding to one or more embodiments of the present invention.

FIG. 9 is a facsimile of exemplary graphical user interface (anddatabase structure) 900 corresponding to one or more embodiments of thepresent invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

This description, which incorporates the Figures and the claims,describes one or more specific embodiments of an invention. Theseembodiments, offered not to limit but only to exemplify and teach theinvention, are shown and described in sufficient detail to enable thoseskilled in the art to implement or practice the invention. Thus, whereappropriate to avoid obscuring the invention, the description may omitcertain information known to those of skill in the art.

Overview

The exemplary system and method embody a unique approach to the designand manufacture of control panels for custom OEM (original equipmentmanufacturer) products, particularly custom HVAC equipment.Conventionally, OEMs develop and offer families of products that addressparticular market segments. For example, OEM's that produce HVACequipment typically offer a family or range of products. Within aproduct family, OEM customers choose from a relatively large number ofoptions. Within each product family, millions of permutations orpotentially unique option combinations are generally possible. Becauseof this variability in product configuration, each OEM product orderedis considered to be at least somewhat unique or custom in terms ofcontent and design.

To bring a highly variable product family to market, an OEM typicallyoperates as follows:

-   -   1) Recognize a market opportunity.    -   2) Define specifications for a product family that meets the        opportunity.    -   3) Detail and design engineering for the product family    -   4) Provide list of options for customers to choose from    -   5) Finalize the design and layout as each individual order is        received (ETO engineer to order process)    -   6) Manufacture, test and deliver product to customer        specifications.

Development of the controls subsystem or control panel for the productfamily follows the same process, specifically steps 2-6.

The exemplary control panel design and manufacturing system streamlinesthe upfront development of control panels for such OEM product families(steps 2, 3 and 4), automates the ETO process (step 5), and provides themanufacturing information and reports necessary for the just-in-timemass production of custom controls panels for OEM products (step 6).

Exemplary Control Panel Design and Manufacturing System

FIG. 1 shows an exemplary control panel design and manufacturing supportsystem 100. System 100 includes a computer workstation 110, anenterprise resource planning (ERP) system 120, and a manufacturingcomplex 130. In the exemplary embodiment, access device 110 takes theform of a personal computer, laptop computer, personal digitalassistant, mobile telephone, or any other devices capable of supportingthe functionality described herein. Specifically, workstation 110includes a processor module 111, a memory 112, a display 113, a keyboard114, and a graphical pointer or selector 115.

Processor module 111 includes one or more processors, processingcircuits, or controllers. In the exemplary embodiment, processor module111 takes any convenient or desirable form. Coupled to processor module111 is memory 112.

Memory module 112, which takes the exemplary form of one or moreelectronic, magnetic, or optical data-storage devices, stores automatedpanel expert (APE) design and manufacturing module 116.

Module 116, which includes machine readable and/or executableinstruction sets and related data, includes a general productspecification module 1161, a product definition data structure 1162,technical specification module 1163, manufacturing support module 1164,and associated graphical user interfaces 1165.

General product (control panel) specification (or configuration) module1161 includes instruction sets and data for producing one or portions ofgraphical user interface (GUI) 1165, accepting user input related toattributes of an HVAC system, and defining and outputting generalproduct specification data structure (DNA) 1162 based on the selectedattributes or on imported attributes or requirements. In the exemplaryembodiment, general product specification data structure takes the formof an encoded text string, which is validated based onoptions-compatibility rules. DNA 1162 is output to technicalspecification module 1163.

Technical specification module 1163 decodes DNA 1162 into various fieldsor segments. These segments are used in automatically selectingcomponents and defining mechanical and electrical schematics for aproduct, such as an HVAC control panel, using design rules and macrosfor computer-aided-design tools.

Manufacturing module 1164, which receives the mechanical and electricalschematics, includes instructions sets and data for not only definingone or more portions of GUI 1165, such as ECAD interfaces, but alsodefining wiring lists, mechanical layouts, ERP order administration,etc.

In addition to workstation 110, system 100 includes ERP system 120 andmanufacturing complex 130, both of which interface with manufacturingmodule 1164 to facilitate just-in-time mass production of HVAC controlpanels and associated wiring harnesses.

Exemplary Method of Operation

FIG. 2 shows a flowchart of an exemplary method 200 of operating asystem 100 in FIG. 1. Flow chart 200 includes blocks 210-240, which arearranged and described serially. However, other embodiments execute twoor more blocks in parallel using multiple processors or processor-likedevices or a single processor organized as two or more virtual machinesor sub processors. Other embodiments also alter the process sequence orprovide different functional partitions or blocks to achieve analogousresults. Moreover, still other embodiments implement the blocks as twoor more interconnected hardware modules with related control and datasignals communicated between and through the modules. Thus, theexemplary process flow applies to software, hardware, and firmwareimplementations.

The exemplary method begins at block 210, which entails receiving inputdefining a set of product options. In the exemplary embodiment, thisentails displaying a product definition or configuration interfaceportion of GUI 1165 which lists a variety product selection option. FIG.3 shows an exemplary configuration interface 300.

Configuration interface 300 includes a product line listing region 310,a feature listing region 320, and a corresponding feature definitionregion 330. Product line listing region lists one or more selectableproduct lines. Feature listing region 320 lists a set of features orattributes, such as voltage-phase-frequency attributes 321, whichassociated with the active or selected product line within region 310.Feature definition region 330 includes a set of feature definitionregions, such as pull-down menu 331, which corresponds to thevoltage-phase-frequency attributes 321. Pull-down menu 331 listsselectable options. Execution continues at block 220.

Block 220 entails defining an equipment data structure based on theselected product options. In the exemplary embodiment this entailsdefining a DNA data structure in the form of a coded text string basedon the selections made using configuration interface portion of GUI 1165or interface 300.

FIG. 4A shows a tabular rendition of an exemplary DNA data structure400, which includes 45 data fields, each associated with a particularuser-selected or otherwise defined OEM product option, such as an OEMHVAC system. In the exemplary character-string implementation, each datafield is associated with a position within the character string and hasa predetermined number of characters representative of some aspect of anOEM HVAC system that affects its control panel (and wiring harness.) Forexample, data field #1 is 9 characters long and defines the model numberof the HVAC system; data field #2 is 3 characters long and defines someaspect of the voltage-phase-frequency of the HVAC system with theselected model number; data field #3 defines some aspect of the HVACdisconnect and has a length of one character. In the exemplaryembodiment, the data field number also indicates its cardinal positionwithin a concatenated text string.

In defining the DNA structure based on the selected options, theexemplary embodiment uses a translation data structure or table. FIG. 4Bshows an exemplary translation data structure 450, which is stored inmemory of the exemplary system. Translation data structure 450 includesoptions 452, code strings 454, and lookup codes 456. In the exemplarysystem, one or more of the user selections for the configuration menu iscalculated based on other selected parameters or selected from a lookuptable using a lookup coding scheme that either addresses a predeterminedvalue or a formula for determining a value. (In the exemplaryembodiment, DNA coding table 450, implemented as a spreadsheet ordatabase, is also used to define the content and sequencing of menus andmenu listings in the configuration interface. Thus, changing theposition of the model number options within the spreadsheet changes itsposition within interface 300.) An exemplary control panel DNA datastructure follows:

-   VPR110D05203N1V00.301.60N00.000.0NA000.000.0000.000.0000.    000.00.0000.000.0NANANCNA00.0NAS00.200.5NNNNNNN

The exemplary method also entails validating the DNA data structureusing validation rules, specifically ensuring that the selected optionspresented in the DNA data structure are compatible based on optionsrules. Some embodiments perform validation during general productspecification on a selection-by-selection basis, alerting the userwhenever a given selection is incompatible with a prior selection, oralternatively narrowing the available feature space as the user movesthrough the configuration interface.

FIG. 2 shows that after defining an equipment data structure based onthe selected product options, execution continues at block 230.

Block 230 entails automatically generating technical design datastructures and documentation based on the defined (and validated)equipment data structure (which is representative of the general productspecification.) In the exemplary embodiment, this generally entailsdefining a parts lists based on the DNA data structure, generatingelectrical and mechanical schematics based on ECAD macros for the partsand related macro attributes logically associated with parts and one ormore portions of the DNA data structure, such as model number or productline.

Block 240 entails automatically manufacturing a piece of equipment, inthis case a control panel, based on the technical design datastructures. In the exemplary embodiment, manufacturing entails definingwiring lists, mechanical layouts, etc. and communicating relativeinstructions sets to one or more automated or robotic manufacturingdevices, such as wiring machine, laser cutter, or milling machine, tocomplete the desired control panel. Additionally, automated testing isperformed.

Further structural and operational details are described below inrelation to an exemplary software architecture.

Exemplary Software Architecture

FIGS. 5A and 5B shows an architectural block and flow diagram of anexemplary implementation 500 of software 116 in FIG. 1. These two figureshows three sets of color coded components, with the green componentsgenerally corresponding to module 1161, the yellow componentscorresponding to module 1163, and the blue components corresponding tomodule 1164. Flow through the diagram is generally left to right.

General Product Specification

In operation, the exemplary method starts with presenting a “designready” list of common technical options (EDB PROGRAM OPTIONS 202) foundwithin an OEM industry such as HVAC, pump, large compressor, conveyor,packaging or air handling etc. For example, an HVAC OEM can selectoptions for a range of supply fans based on horsepower. (FIGS. 3 and 4shows respective graphical user interfaces 300 and 400 for selectingoptions.)

By choosing from this list of options and limiting the availableselections within each option, the OEM can use the exemplary system toquickly define and generate the general engineering specifications for aproduct family (Step 2 in Overview). In the exemplary embodiment, theOEM can further develop the engineering product family specifications byadding to this list any additional options that may be unique to itsoffering.

Because the system helps reduce the time and cost of upfront productdevelopment (Step 3) and ETO (step 5), OEMs are often able toeconomically expand the number and variety of product family options(EDB PROGRAM OPTIONS 2021). Once a set of options is defined, the systemdefines a DNA code string or data structure 208 (analogous to DNA 1162in FIG. 1) that effectively captures the customized order from the OEM'scustomers.

More specifically, in the exemplary embodiment, an APE CONFIG DLL module503, reads the original engineering specifications from an OPTIONSDATABASE 502 and automatically defines a Control Panel DNA datastructure 508) for the product family.

To capture an order, the exemplary system configures the EDB PROGRAMOPTIONS preselected by an OEM into a dynamic GUI interface list, such asGUI 300 in FIG. 3 This GUI is used for manually configuring orders (Step4) through the selection of control panel options (ORDER CONFIGURATION,ORDER CONFIGURED MANUALLY). Selection listed in the GUI 300 arepopulated from an EDB program options database 5051. FIG. 6 shows thatthe EDB program options database can take the form of an Excelspreadsheet; however, some embodiments use a SQL database format.

The EDB program options database contains the list of options orparameters that are used to define translation table in FIG. 4B, whichas noted earlier to translate selected equipment options into the DNAcode string for a control panel. Some of these options are displayeddynamically through the configuration interface in FIG. 3 when someoneconfigures a control panel. These are the options highlighted in yellowin FIG. 4. The ones highlighted in orange/tan are calculated on the flyor using lookup tables kept in other Microsoft Excel spreadsheet files.In many cases, the user need not be prompted. For example, the exemplaryembodiment calculates amperage if we prompt for voltage and horsepower.In this case, the DNA strand will show horsepower, voltage and amperageeven though we only prompted the user for horsepower and voltage. All ofthe parameters are used to complete the fields in the DNA strands. EDBfiles are fully customizable for each individual customer's controlpanel requirements

The exemplary system offers a unique link between how a customer viewsrequirements and how these requirements translate into a set ofengineering specifications in the form of a PANEL DNA CODE STRING. Forexample, a customer may view a requirement as the need for an HVACsystem for a 25,000 sq. ft. warehouse, and the exemplary systemultimately translates this into an engineering requirement of an HVACsystem having 4 units of a specified capacity with each unit having 5 hpsupply fans.

The exemplary system presents options to a customer in a menu usingcustomer friendly language and then uses RDB OPTIONS RULES 5022 withinOPTIONS DATABASE 502 to translate or map the customer requirements intothe engineering requirements. For example, the system can query acustomer for the size of warehouse they need air conditioned and inresponse select an appropriate quantity and product recommendation basedon model number. From the model number, the exemplary system providesfurther rules to select more detailed engineering criteria such assupply fan horsepower etc. This automated translation from customerrequirements to engineering specifications enables the OEM to quicklyidentify customer requirements and instantly provide customizedengineering specifications including quotes and bills of material(BOMs).

In exemplary embodiment, APE CONFIG DLL 504 used to map customerrequirements and configure orders into Panel DNA code string 508 canalso be embedded or called directly from an OEM's internal order entrysoftware as represented by CUSTOMER GENERATED PRODUCT DNA 509. The APEGUI interface can be hosted on a web server to define a WEB CONFIGUREDORDER 510, allowing OEM customers to order products from anywhere via awide- or local-area network.

To detect and allow correction of compatibility issues between selectedoptions, APE RULES.DLL 510 reads the list of options selected withinPANEL DNA CODE STRING 508 and dynamically checks for errors and optionincompatibilities, using engineering rules within RDB OPTIONS RULESdatabase 5022 to validate each potential order. DNA VALIDITY CHECKinterface 511 is used in concert with the ORDER CONFIGURATION interface506 to guide OEM sales personnel and their potential customers throughthe order configuration process. (In some embodiments, the APE RULES.DLLcan also be used in concert with and be directly called from an OEM'sinternal order-entry software tool.)

More specifically, RDB OPTIONS RULES database 5022 includes a series ofif/then Boolean operations that point to fields in the PANEL DNA CODESTRING. For example if field one equals 30 (which could stand for amodel number 30 pump control) then perhaps field 2 cannot be X, Y, or Z(which could represent certain types of disconnects). Each ruleviolation points to an error message that can be dynamically displayedto the user as a DNA ERROR REPORT 512 from the DNA VALIDITY CHECKinterface 512. For example; “Error you cannot have a type X, Y or Zdisconnect in a model 30 product.” FIG. 7 shows an exemplary DNA errorreport GUI 700 (300), with an error message region 710.

When APE RULES.DLL 510 determines that all the rules in RDB OPTION RULESdatabase 5022 have been met for a particular order defined by PANEL DNACODE STRING 508, it validates the DNA code string and clears the order,now captured in the VALID DNA format, for use with the automated ETOprocessing tools. FIG. 8 shows an exemplary valid DNA GUI 800 that isoutput in response to a validity confirmation.

FIG. 9 shows an exemplary spreadsheet version 900 of RDB option rulesdatabase 5022. The rules are set up as complex sets of IF-THENstatements of the form IF (DNA code (=, <, >, etc) some calculatedvalue) THEN (select size, part, macro, wire, etc). (Rules of this formcan also be created and managed using off-the-shelf applications such asRules Stream expert-system software.)

These are the rules that are executed against a DNA code string. In somecases the rules describe DNA code compatibility and which options may ormay not work with others. In this case they are used in the DNA errorchecking routines that validate a desired configuration or DNA codestring. In other instances these rules are used to select and sizecomponents that go into a control panel. For example if the DNA code forhp=30 then a motor starter of a certain size from a particular venderwill be selected. When we use the RDB format for such selections wesometime refer to the file as a DWEEEB database.

Detailed Technical Design Specification

The upfront engineering of the controls for an OEM family of productstypically involves creating the following:

-   -   A) A series of general yet detailed electrical schematics that        cover the options and basic controls functions necessary for the        OEM product family.    -   B) A complete list of all the components and parts that are        potentially needed to complete the control panels for an entire        OEM product family.    -   C) A detailed scheme for the physical layout, of the parts from        step B, for the family of control panels.

The exemplary process and software tools are designed to help streamlinethe upfront detailed design process (Steps A, B & C) and automate theETO process. The exemplary system automates the process in such a waythat the detailed design information from steps A, B and C are captured(MACRO OBJECT DR, APE MASTER ENGINEERING PARTS DB and MACROS along withETO engineering or decision making expertise (DWEEEB database withelectrical engineering and estimating brains DATABASE) within thesystem. The system incorporates off-the-shelf, 3D solid-modelingapplications (SOLIDWORKS 3D LAYOUT) for interference checking and thedevelopment of a layout scheme. (Step C).

The detailed design process (steps A, B, C) is therefore streamlined toa standardized process of selecting appropriate generic macros and rulesand augmenting them with any additional data necessary to complete thedesign of the controls for a family of products. (Note: ECAD macros aresmall schematic or layout drawings that can be picked, placed and linkedinto complete schematic and layout drawings.) Once populated with thedetail design information and ETO rules, the exemplary system completelyautomates the ETO process and produces as-built schematics, as-builtlayouts, BOMs, and a host of manufacturing reports for each unique panelat the touch of a button (SCHEMATICS, LAYOUTS, BOM, LABELS, WIRE LISTS,MFG REPORTS).

Automated Manufacturing

In general terms, the exemplary system captures the expertise andcriteria used by ETO engineers and processes orders (VALID DNA) withthis information. Instead of an engineer handing off marked upschematics to a drafter, the exemplary system uses the APE GUI ECADINTERFACE, APE (APE PROMISE DLL, APE EPLAN DLL) to create an ECADinstruction set (PROMISE INSTRUCTION SET, EPLAN INSTRUCTION SET) thatcan be executed through the API (application programming interface) ofstandard off the shelf ECAD drafting packages (APE PROMISE API, APEEPLAN API). Through the APIs, as-built schematics and layouts can begenerated with the touch of a button or via a single command or callfrom another application. The schematics and layouts are thenefficiently checked for errors and completeness utilizing standardutilities available within the ECAD packages (ECAD ENVIRONMENT).

The exemplary system includes a unique populated master parts database(APE MASTER ENGINEERING PARTS DB) that is associated with a unique setof macro information or MACRO OBJECT DATA BASE and a catalog of ECADmacros (MACROS, MACROS/PLACEHOLDER).

Electrical CAD systems such as PromisE, EPLAN or AutoCAD electric usethe concept of Macros or sub drawings that can be quickly accessed tobuild up larger or complete schematics. In addition to the graphicalrepresentation, each software vender allows data or attributes to beassigned to a macro. This information can include items such as partnumbers of components, wire numbers, wire gauge, wire colors, harnessdesignations, schematic page and X,Y location coordinates, device IDs,connection point labels, wire terminations, strip lengths, wire lengths,etc.

Conventional macros contain this type of attribute information on aproduct family basis. Thus, conventional macro catalogs normally need tobe recreated for each different product family or schematic and layoutdesign. However, the present inventors recognized the inefficiency ofthis approach and devised a unique MACRO OBJECT DATABASE that captures,maintains and manages ECAD macro attribute information. This allows oneto create truly generic catalogs of macros (with generic placeholdersfor the attribute information) for all off-the-shelf ECAD packages.These generic macros can be used repeatedly across various OEMs andacross various product families as well as schematic and layoutconfigurations. Once generic macros are placed, information specific tothe product family can be assigned to the macros from the MACRO OBJECTDATABASE.

The benefits and efficiencies of this unique approach are many. The needto redraw and manage macros used for specific product families isreduced. An original design manufacturer can share generic macros acrossproduct families and customers reducing upfront development costs. ECADattribute data is managed independently from any specific ECAD softwareapplication, thus allowing the ability to change an APE installationfrom one ECAD software vender to another. And by managing the attributedata within a sophisticated database utility, such as the Microsoft SQLutility, the data is much easier to maintain, update and revise. Andthose that maintain this attribute data can do so directly withouthaving to access or even know how to access the ECAD softwareapplications, again reducing engineering time, resources and expertiserequired for implementing initial installations of the APE system orfuture engineering changes in a product family.

Associated with each part in the master library and with each macro is aset of rules (DWEEEB DATABASE) that describe what parts and what macrosmay be selected for any given VALID DNA code string. The rules include aseries of if/then Boolean operations, which once satisfied point to apart (PARTS SELECTOR) to be included in the BOM or a macro (MACROSELECTOR) to be included in the as-built SCHEMATICS or LAYOUTS.

As the APE PROMISE DLL or APE EPLAN DLL processes each rule (DWEEEBDATABASE) against an order (VALID DNA), instruction sets for the pickingand placing of macros and the assignment of parts (PROMISE INSTRUCTIONSET, EPLAN INSTRUCTION SET) and ECAD attributes are generated as inputfor the ECAD systems (PROMISE APPLICATION, EPLAN APPLICATION). Throughthe ECAD APIs, (APE PROMISE API, APE EPLAN API), the instruction setsare automatically executed and as-built drawings, BOMs and manufacturingreports (SCHEMATICS, LAYOUTS, BOM, LABELS, WIRE LISTS, MFG REPORTS) aregenerated without the need for manual intervention (ECAD INTERFACE).Results are verified within the ECAD ENVIRONMENT and then electronicallysent to the appropriate manufacturing group (ECAD INTERFACE).

As-built manufacturing reports (SCHEMATICS, LAYOUTS, BOM, LABELS, WIRELISTS, MFG REPORTS are archived (PROCESSED JOB LIBRARY) using the APE DBSYNC DLL and DB SYNC interface for future aftermarket and support access(AFTER MARKET WEB INTERFACE, REPLACEMENT PART PO).

The handling of macros is a notable aspect of the exemplary system. Incontrast to conventional ECAD systems which bundle macros and macroattributes, the exemplary embodiments effectively separates them,storing product-line-specific macro attributes in a separate databasethat can be called by the ECAD APIs. The ECAD systems include thedrawings macros for relevant components along with their conventionalmacro attributes; however, when ECAD APIs in the exemplary embodimentcall for a particular macro from an ECAD program, they also call for orretrieve a set of product-line-specific macro attributes from the macroattribute database (DWEEEB in FIG. 5A). The conventional macroattributes are ignored or overridden by the ECAD API according to theproduct-line-specific macro attributes. Thus, in the exemplaryembodiment, ECAD macros can be paired with multiple sets ofproduct-specific macro attributes that effectively redefine the macro asnecessary to facilitate the production of schematics and as-builtdrawings for not only multiple product lines of a given OEM, but alsoacross the product lines of multiple OEMs.

The overall advantages to this system includes ETO turn-around timesmeasured in minutes versus days or even weeks, fewer human touches andtherefore fewer errors in the drafting process, complete manufacturingand after-market support specifications in the form of as-builtdrawings, BOMs and manufacturing reports (SCHEMATICS, LAYOUTS, BOM,LABELS, WIRE LISTS, MFG REPORTS), and a system that continually improvesthrough the iterative process of quality control.

Extensions Pricing Tool Extensions

Pricing information can optionally be added to the master parts list(ERP PARTS INFO DB). Along with PARTS SELECTOR rules, the exemplarysystem uses a QUOTING DLL and QUOTING/PRICING TOOL GUI interface tocalculate and display pricing information (CONTROL PANEL BOM, CONTROLPANEL QUOTE) when the sales organization configures an order (VALIDDNA). This capability to generate instant quotes at the time an order isconfigured for custom control panels is another competitive advantage.

Harness and Wire Processing Extensions

If control panels can be thought of as the brains and the OEM product asthe body, then harnesses that connect the brains to the body can be seenas the nervous system. For each potential control panel within an OEMproduct family, there is a unique set of corresponding harnesses thatare required to connect the control panel to the OEM product.

The exemplary system includes a harness parts and pricing rules database(HDB HARNESS, HDB COMPONENT PRICE) that is processed (HARNESSES GUI)with the APE HRNS DLL to create both quotes (EXT HARNESS QUOTE) andmanufacturing reports (HRNS PROD FLOOR REPORT, HRNS LABEL REPORT) forthe external harnesses. Harness production floor reports may includeinstruction sets for use with automated wire processing machines.

While most of the harness information can be captured in a design readyformat, the lengths of the harnesses are dependant on the size, shapeand electrical routing within the ordered OEM equipment. Through theexemplary system, OEMs can choose to include this additional harnessinformation (CUSTOMER GENERATED EXTERNAL HARNESS INPUT FILE) along withthe control panel configuration (VALID DNA+HARNESS).

In addition to harnesses data, a set of control panel wire information(WDB WIRES) can also be created for the product family. This set ofdata/rules is used by the APE WIRE MACHINE DLL to compile amanufacturing wire report (WIRE PRODUCTION FLOOR REPORT) and a set ofinstructions for an automated wire process machine. The exemplaryembodiment supports the Schleneger brand of wire machine (SCHLENEGERINTERFACE, SCHLENEGER INSTRUCTION SET), but the system architectureallows that others such as Komax can added. The use of automated wireprocessing machines drastically reduces the time to cut, strip, labeland terminate wires.

Database Synchronization

The exemplary system manages and synchronizes the databases used throughout the specification, detailed design, ETO process and manufacturingprocess (Steps 2-6) and future aftermarket activities. Through the PARTSDATABASE ENVIRONMENT and the DB SYNC GUI interface, APE establishesindustry libraries of design-ready data, manages historic productiondata, and synchronizes information with internal, supplier and customerorder to remittance applications.

The exemplary system also helps differentiate and manage both commercialand engineering data for parts. On the commercial side, the systemrecognizes a central ERP (enterprise resource planning) system as thesource for current parts, pricing and scheduling information (M1APPLICATION).

While the ERP system specializes in commercial information, there isstill a need to manage the engineering data such as part specifications,mounting whole locations, connection point specifications etc. In manycases, the ECAD software applications have proprietary databaseutilities to manage this type of parts data. Similar to the MACRO OBJECTDATABASE, the exemplary system employs a more generic APE ENGINEERINGPARTS DB that can manage generic parts data across multiple productfamilies, customers, vendors and ECAD software applications, all whilebeing seamlessly synchronized with an ERP system.

The exemplary system uses this information (ERP PARTS INFO DATA) topopulate and refresh the design ready master libraries (MACRO OBJECT DB,ENGINEERING PARTS DB and DWEEEB DATABASE PARTS SELECTOR). Through the DBSYNC interface, the APE DB SYNC DLL extracts information from the ERPsystem (APE M1 API), combines this information with the APE ENGINEERINGPARTS DB and is makes all necessary data available and accessible by theECAD ENVIRONMENT, QUOTING TOOLS, MFG REPORTS generation such as BOMs,and aftermarket part selection utilities such as the AFTER MKT WEBINTERFACE.

As orders enter the ETO engineering process, the orders are in parallelmanaged from a supplier and order-to-remittance perspective. Electroniccommunication from the exemplary system generates purchase orders (Pos)for components (PART PO) and automatically sends them to suppliers,manages inventories (XML ELECTRONIC SUPPLIER BOMS, PICK LISTS), andcoordinates schedules (MFG SCHEDULES, MFG REPORTS) between themanufacturing department and OEM customer.

As jobs are complete through the automated ETO process embodied withinthe system, manufacturing reports (SCHEMATICS, LAYOUTS, BOM, LABELS,WIRE LISTS, MFG REPORTS) and project data (ECAD PROJECTS) are stored ina PROCESSED JOB LIBRARY. This library can in turn be accessed throughthe DB SYNC interface for future reference. An additional web portal(AFTER MKT WEB INTERFACE) to this historic project data is available foraftermarket support and the generation of REPLACEMENT PART POs.

Final Test and PLC Logic

The exemplary system also assists in the final programming and testingof the panel before it leaves for the OEM customer. Once the panel isassembled, the APE PLC LOAD AND TEST interface utilizes the APE MFG PLCDLL to download the correct controller instructions (PLC LICENSEINSTRUCTION SET) to the panels PLC (programmable logic controller) andthen tests the panel to make sure it is functionally correctly (PANELTEST). Thus, testing protocols or instructions are dynamically loaded tomatch the particulars of any given panel under test.

Full Customization

The exemplary system enables “true custom” design and manufacturing byproviding for manual interface into the ECAD applications. Specifically,the system can be used to define a semicustom product using theconfiguration interface to define a product DNA structure and develop adetailed technical design, including ECAD schematics. The ECADschematics can then be manually modified to include options notavailable in the configuration interface. Once the schematics are fullycustomized with these options, they and related BOMs, etc can begenerated as with any product defined fully in the configurationinterface. This customization process also applies to mechanical layoutand enclosure dimensioning and design, with the exception that 2D or 3Dmodeling software can be used to manually or automatically generatelayouts and enclosure designs after determination of electricalschematics and BOMs. The system can process these technical design usingits manufacturing and ERP automation as with semicustom designs.

CONCLUSION

The embodiments described above and in the claims are intended only toillustrate and teach one or more ways of practicing or implementing thepresent invention, not to restrict its breadth or scope. The actualscope of the invention, which embraces all ways of practicing orimplementing the teachings of the invention, is defined only by theissued claims and their equivalents.

1. A method comprising: receiving into a computer processor a set of twoor more product options; and automatically generating in a memorycoupled to the computer processor a coded product data structure basedon the received set of two or more product options, the coded productdata structure including data relating to electrical and mechanicalparameters of a product.
 2. The method of claim 1, wherein the product,the product options, and the coded product data structure relate to aheating, ventilation, and air conditioning (HVAC) product.
 3. The methodof claim 1, wherein the product and product options are associated withan original equipment manufacturer (OEM).
 4. The method of claim 1,wherein automatically generating in memory the coded product datastructure comprises using one or more of the received set of productoptions to identify information in a translation data structure.
 5. Themethod of claim 4, wherein the translation data structure identifies atleast one predetermined value or a formula for determining a value. 6.The method of claim 1, comprising automatically generating one or moreof an electrical schematic and a mechanical schematic based on the codedproduct data structure.
 7. The method of claim 6, wherein one or more ofthe electrical schematic and the mechanical schematic define at least aportion of a product control panel.
 8. The method of claim 7, whereinone of more of the electrical schematic and the mechanical schematicdefine at least a portion of a harness for coupling the product controlpanel to the product.
 9. The method of claim 6, wherein automaticallygenerating one or more of the electrical schematic and the mechanicalschematic comprises: automatically defining a parts list of two or moreparts based on the coded product data structure; automaticallyretrieving, based on at least one of the parts in the parts list, amacro for an electronic computer aided design system; and automaticallygenerating one or more of the electrical schematic and the mechanicalschematic based on the retrieved macro.
 10. The method of claim 9,wherein automatically retrieving the macro comprises: retrieving themacro from a macro database, wherein each macro in the macro database islogically associated with a generic macro placeholder; and accessing aset of macro attributes based on a model number associated with at leastone of the parts.
 11. The method of claim 7, comprising: generatingassembly instructions using engineering design rules and the codedproduct data structure; generating and ordering parts using the codedproduct data structure and an enterprise resource planning system; andcommunicating the assembly instructions to robotic manufacturingequipment.
 12. The method of claim 11, comprising: receiving in thecomputer processor the assembly instructions; and manufacturing theproduct using the robotic manufacturing equipment.
 13. The method ofclaim 12, comprising: receiving into the computer processor instructionsfor the product control panel; and testing the product control panelusing the instructions.
 14. The method of claim 1, comprising validatingdata in the coded product data structure to verify that the two or moreoptions are compatible as a function of a set of option rules.
 15. Themethod of claim 1, comprising generating a product price quote using thecoded product data structure.
 16. The method of claim 1, wherein theelectrical and mechanical parameters comprise one or more of a modelnumber, voltage-phase-frequency data, a disconnect, a fan type andquantity, a condenser type, a damper, gas heat data, an electrictempering coil, electric heat data, heat recovery data, enthalpy wheelphase data, a compressor crankcase, a ground fault circuit interrupter(GFCI) outlet, and head pressure control data.
 17. A computer readablemedium comprising instructions that when executed by a computerprocessor execute a process comprising: receiving a set of two or moreproduct options; and automatically generating a coded product datastructure based on the received set of two or more product options, thecoded product data structure including data relating to electrical andmechanical parameters of a product.
 18. The computer readable medium ofclaim 17, wherein the product, the product options, and the codedproduct data structure relate to a heating, ventilation, and airconditioning (HVAC) product; and wherein the product and product optionsare associated with an original equipment manufacturer (OEM).
 19. Thecomputer readable medium of claim 17, comprising automaticallygenerating one or more of an electrical schematic and a mechanicalschematic based on the coded product data structure; wherein one or moreof the electrical schematic and the mechanical schematic define at leasta portion of a product control panel.
 20. A system comprising: acomputer processor configured for receiving a set of two or more productoptions; and a computer processor configured for automaticallygenerating a coded product data structure based on the received set oftwo or more product options, the coded product data structure includingdata relating to electrical and mechanical parameters of a product